US6331678B1 - Reduction of blistering and delamination of high-temperature devices with metal film - Google Patents
Reduction of blistering and delamination of high-temperature devices with metal film Download PDFInfo
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- US6331678B1 US6331678B1 US09/429,051 US42905199A US6331678B1 US 6331678 B1 US6331678 B1 US 6331678B1 US 42905199 A US42905199 A US 42905199A US 6331678 B1 US6331678 B1 US 6331678B1
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0271—Arrangements for reducing stress or warp in rigid printed circuit boards, e.g. caused by loads, vibrations or differences in thermal expansion
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0306—Inorganic insulating substrates, e.g. ceramic, glass
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/11—Printed elements for providing electric connections to or between printed circuits
- H05K1/111—Pads for surface mounting, e.g. lay-out
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/03—Conductive materials
- H05K2201/0302—Properties and characteristics in general
- H05K2201/0317—Thin film conductor layer; Thin film passive component
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/03—Conductive materials
- H05K2201/0332—Structure of the conductor
- H05K2201/0364—Conductor shape
- H05K2201/0373—Conductors having a fine structure, e.g. providing a plurality of contact points with a structured tool
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/06—Thermal details
- H05K2201/068—Thermal details wherein the coefficient of thermal expansion is important
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/38—Improvement of the adhesion between the insulating substrate and the metal
- H05K3/388—Improvement of the adhesion between the insulating substrate and the metal by the use of a metallic or inorganic thin film adhesion layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/901—Printed circuit
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24917—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including metal layer
Definitions
- the present invention is related to techniques for forming high temperature devices that have films of dissimilar thermal expansion coefficients adhered together, more specifically, for forming sensor devices which are used in high-temperature operation and which are formed by a method in which metal films are processed under high temperature.
- metal thin films and filaments are very common in measurement and sensing devices, such as flow and velocity sensors.
- a hot conductor thin filament that can dissipate heat is held in a fluid stream.
- the conductor filament loses heat to the fluid stream, its temperature falls.
- the resulting change in electrical resistance of the conductor filament associated with the fall in temperature can be measured and it would be indicative of the flow characteristics of the fluid stream.
- conductor filaments are made from conductor thin films.
- a variety of metals can be used for making the conductor filament (or thin film).
- platinum is preferred over other metallic substances because of its refractory nature as well as its high electrical resistance and temperature coefficient of resistance (TCR). It is also inert and can operate at a high temperature.
- the platinum thin film is made by deposition on a surface and during the subsequent fabrication of the measurement or sensing device, it may be necessary to anneal the deposited thin film at a high temperature. Annealing improves the material properties of thin film platinum. It typically reduces the resistance and increases the thermal coefficient of resistance of the thin film to close to the bulk value.
- the annealing typically takes place at temperatures at or above 800° C. At this high temperature, due to thermal expansion mismatch of the thin metal film with the substrate (i.e., the material supporting the thin metal film), high stress results in the film and at the interface. The stress can be so high as to cause the metal to totally come off (delaminate) or blister from the substrate. If a platinum thin film is used to form one of the layers of electrical contact pads, the poor adhesion of the platinum on the underlying dielectric material causes a weak link that can result in bond pad failure. On a metal film attached to a dielectric material having a different coefficient of expansion from that of the metal film, blistering and protrusions (hillocks) can form when the metal film experiences high temperature fluctuation.
- a micro-mesh structure is used to reduce the interfacial stress and improve the adhesion of a conductor metal to a dielectric material.
- a device having such a micro-mesh structure is provided and the method for making it is provided in the present invention.
- a device includes a component (for example, a bond pad, i.e., conductor pad) having a micro-mesh of conductor metal (sometimes referred to as “micro-mesh conductor metal” herein) contacting another conductor metal (which may be a metal different from the micro-mesh conductor metal, such as the conductor metal of a bond pad) to provide electrical communication to the micro-mesh.
- the second conductor metal preferably without a micro-mesh structure of its own, adheres to the micro-mesh and the dielectric layer through the openings in the micro-mesh.
- the present invention provides improved adhesion between the conductor metal and the dielectric material by using an adhesive layer sandwiched between the dielectric material and the micro-mesh conductor metal. This is especially useful in adhering platinum to a dielectric material such as silicon nitride.
- the micro-mesh conductor metal is sandwiched between two adhesive layers. Lines (or branches) in the micro-mesh have a cross-section in which the top adhesive layer (which will face a bond pad metal) has a smaller width than that of the micro-mesh conductor metal. In turn, the micro-mesh conductor metal has a smaller width than that of the bottom adhesive layer, which is nearest a supporting substrate. In this way, the bond pad (conductor pad) metal can has contact with the adhesive material and the micro-mesh conductor metal to maintain mechanical integrity and electrical communication.
- a device according to the present invention is operable at a temperature of at least 250° C. or higher without the first electrical conductor delaminating or blistering from the dielectric layer.
- this technique of utilizing a micro-mesh reduces the risk of delamination of platinum on silicon nitride when platinum on dielectric (such as silicon nitride) is annealed at high temperature, for example, as in forming and annealing a layer of silicon nitride to encapsulate the platinum.
- the micro-mesh design also enables devices utilizing a noble metal thin film electrical conductor layer to operate at high temperature in repeated cycles without delamination.
- the application of the micro-mesh of the present invention is particularly advantageous in integrated circuits using a flip-chip technique.
- FIG. 1 is a schematic representation showing an embodiment of a sensor device of the present invention.
- FIG. 2 is a schematic representation showing a heater connection in an embodiment of a sensor device of the present invention
- FIG. 3 is a schematic representation showing a heater connection to bonding pads in the embodiment of FIG. 2 .
- FIG. 4 to FIG. 13 are sectional views in portion showing the different stages of how a heater and bonding pad similar to those in FIG. 3 are made.
- FIG. 14A is a sectional view showing an embodiment of how the bond pad conductor metal is secured to the micro-mesh conductor metal.
- FIG. 14B is a sectional view showing another embodiment of how the bond pad conductor metal is secured to the micro-mesh conductor metal.
- FIG. 15A to FIG. 15C are schematic representations of embodiments of grid configuration of the micro-mesh of the present invention.
- FIG. 16 A and FIG. 16B are schematic representations of certain other embodiments of grid configuration of the micro-mesh of the present invention.
- FIG. 17 shows a conductor portion of a flexible circuit having a metallic micro-mesh attached to a polymeric dielectric material layer.
- the metallic substance By incorporating a micro-mesh structure of a metallic substance that is attached to a dielectric layer, the metallic substance can be secured to the dielectric layer without blistering or delamination. Further, bond pads (conductor pads) of the present invention can operate under high temperature and not result in the conductor metal (e.g. platinum) delaminating from the dielectric material supporting it. It is to be understood that the micro-mesh structure of the present invention can be used to make sensors (including flow sensors, chemical sensors, thermal conductivity detectors), heaters, semiconductor devices, and bonding pads, such as those described in U.S. Pat. No. 4,501,144 (Higashi et al.), U.S. Pat. No. 4,683,159 (Bohrer et al.), U.S.
- FIG. 1 shows, for illustrative purpose, the embodiment of a sensor 100 including heater A 102 and heater B 104 , which are electrically connected to power supply A 106 and power supply B 108 , respectively.
- power supply A 106 and power supply B 108 are electrically connected to a processor 110 , which can determine the energy, voltage, current, and the like, supplied by the power supplies 106 , 108 to the heater 102 , 104 .
- the processor can include, for example, a microprocessor, computer (such as a personal computer, minicomputer, mainframe computer, etc.), and the like. It is to be understood that the power supplies 106 , 108 and the processor 110 can be integrated as a single unit so that the energy output of heaters can be measured by the unit. As used herein, unless specified otherwise in context, the terms “conduct,” “conductor,” and “conductive” refer to electrical conduction.
- FIG. 2 illustrates an embodiment of how a heater in the flow sensor of FIG. 1 can be electrically connected to a power supply.
- a heater 112 e.g., heater 102 or heater 104 of FIG. 1
- a resistor is electrically connected at its two electrical terminals via conductor A 114 and conductor B 116 to electrical bond pad (conductor pad) A 118 and electrical bond pad B 120 respectively.
- Connection by external electronics e.g., for power supply or signal transmission
- to the bond pad can be via wire bonding, flip chip bonding, soldering, and the like.
- FIG. 3 shows a schematic representation of the circuitry 122 in portion of the sensor having heat sensor 112 and conductor A 114 , conductor B 116 , and their respective bond pads 118 , 120 shown in FIG. 2 .
- Heater 112 includes a resistor 124 (in FIG. 3) electrically connected to bond pad A 118 and bond pad B 120 via conductor micro-mesh A 126 and conductor micro-mesh B 130 , respectively.
- the resistor 124 has a serpentine shape.
- the line width of the resistor 124 is about 10 microns, although other widths can be used and will be apparent to one skill in the art based on the present disclosure.
- Bond pad A 118 and bond pad B 120 each include a layer of gold 132 laid on top of an adhesion film of a material such as titanium-tungsten (Ti—W).
- Ti—W film is typically about 200 ⁇ to 500 ⁇ thick.
- Ti—W is a standard adhesion promoting material for attaching thin film gold onto materials such as silicon nitride, oxides or silicon oxynitrides, as well as to platinum.
- the Ti—W film is in turn laid on top of part of the electrically conductive micro-mesh (i.e., conductor micro-mesh 126 or 130 ), as in the area of a bond pad.
- the conductor metal layer when a “conductor metal layer” is laid on a nonconductive adhesive layer (such as an oxide, e.g., TiO 2 ) or to a dielectric material such as silicon nitride, it is contemplated that the conductor metal layer that contains gold may include a Ti—W adhesion promoting metal film between the gold and the nonconductive adhesive layer or between the gold and the dielectric material.
- a nonconductive adhesive layer such as an oxide, e.g., TiO 2
- the conductor metal layer that contains gold may include a Ti—W adhesion promoting metal film between the gold and the nonconductive adhesive layer or between the gold and the dielectric material.
- the conductive micro-mesh 126 and 130 are constructed in a grid pattern 134 .
- the resistor 124 is also electrically connected to other electronic components and circuits 136 for operating, controlling and collecting information from the resistor 124 .
- Using a micro-mesh instead of a continuous strip of conductor to connect the resistor 124 to a bond pad enables the conductor A 114 and conductor B 116 to accommodate more stress, thus to maintain on an underlying dielectric material without delaminating. Comparing to a solid strip of conductor of similar electrical resistance, the micro-mesh has substantially smaller line width in the conductor lines (branches, e.g., 10 microns).
- micro-mesh reduces the compressive stress that can build up in the thin platinum film during the annealing process and later in the high temperature operating condition.
- the term “micro-mesh” refers to a structure that has interconnecting branches (or lines) such that electricity can travel from one end of the micro-mesh to the other end through the branches (or lines).
- a micro-mesh has a line or branch width in the micron range, i.e., smaller than 1 mm. Examples of micro-mesh patterns are shown in FIGS. 15A-15C and FIGS. 16A-16B. Since the branches (or lines) may or may not overlap, there are void areas between some of the branches or lines through which other materials can pass through in the construction of a multiple layers component.
- the resistance in the micromesh can be kept low.
- the resistance from the conductor A 114 and conductor B 116 to the bond pad A 118 and conductor B 120 can be kept low.
- the term “interconnect” as used herein refers to two or more lines or branches connecting together to form portions of the micro-mesh and it is not necessary that all the lines (or branches) connect together at the same point. It is also to be understood that a variety of line (or branch) widths can be used for the interconnecting branches in the micro-mesh conductor micro-mesh A 126 and conductor micro-mesh B 130 .
- a line width of about 2 microns to 200 microns can be used.
- the line width is preferably less than 100 microns, more preferably about 5 microns to 50 microns, and even more preferably about 5 microns to 20 microns.
- the separation (gap) between neighboring lines (or branches) of the micro-mesh is about 0.2 micron to 200 microns, preferably about 2 microns to 20 microns. It is to be understood that the line width for the resistor 124 can also vary for similar design reasons as those of the conductor micro-mesh A 126 and conductor micro-mesh B 130 , as well as for allowing optimal fluid flow and access around the resistors.
- FIG. 4 to FIG. 13 show sectional views of an embodiment illustrating the construction of a portion of a heater with connections for electrical contacts.
- the sectional views of FIG. 4 to FIG. 13 generally correspond to a section along line A′B′ of FIG. 3 to show the cross-section of lines (or branches) of the micro-mesh, although for the sake of clarity in drawing, not all features of FIG. 13 have a corresponding feature in FIG. 3 . It is also noted that the figures are not to scale for the sake of clarity in showing specific features.
- FIG. 4 shows in sectional view in portion of a silicon substrate 138 having a first silicon nitride layer 140 , first adhesive layer 142 , a platinum film 144 to provide electrical conductivity, and a second adhesive layer 146 .
- the inclusion of the adhesive layers 142 and 146 improves the adhesion of the platinum film 144 to a dielectric material (e.g., silicon nitride layer 140 .
- the subsequent structuring of the platinum film 144 into a micro-mesh further facilitates the maintenance of adhesion at high temperatures, e.g., at or above about 200° C., more particularly at or above about 300° C.
- a patterned photoresist layer 148 lies on top of the second adhesive layer.
- a dielectric layer such as the first silicon nitride layer 140 e.g., a 0.5 micron thick layer of LPCVD silicon nitride is laid on top of the substrate 138 .
- LPCVD Low Pressure Chemical Vapor Deposition
- a gas mixture is passed into a chamber containing the substrate on which a material is being deposited. The chamber is maintained at low pressure and high temperature. The gas molecule will break down and recombine to form the material desired.
- a typical gas mixture would be ammonia (NH 3 ) and silane (SiH 4 ).
- silane is diluted with nitrogen for safety reasons.
- the chamber is heated to 850° C.
- NH 3 and SiH 4 will react to form silicon nitride, Si 3 N 4 , with hydrogen purged.
- chlorosilane SiH 2 Cl 2
- Si 3 N 4 can be used instead to form Si 3 N 4 .
- An adhesive layer 142 is formed subsequently.
- a 300 ⁇ layer of TiO 2 is sputtered on the dielectric layer 140 and annealed in an oxygen atmosphere at 700° C. for 3 hours. The annealing ensures that the adhesive layer 142 is adequately oxidized to TiO 2 .
- a metallic conductor layer is formed, e.g., by evaporating platinum and depositing a 1000 ⁇ film on the adhesive layer of TiO 2 .
- the platinum film can alternatively be formed by sputtering.
- the platinum film is formed on the dielectric layer with a slight tension. This can be achieved by heating the material receiving the platinum to a moderate temperature, e.g., about 300° C. to 400° C.
- the stress in a sputtered platinum film can also be controlled by changing the pressure in the sputtering chamber. A small tension will cause less of compression on the dielectric layer for any subsequent treatment at high temperature (e.g., at 850° C.).
- Another adhesive layer 146 of TiO 2 is sputtered on the metal layer (e.g., platinum film).
- the photoresist is patterned on the second adhesive layer 146 by standard techniques for depositing the photoresist, irradiating a pattern on the photoresist, developing it, and removing the undeveloped material.
- FIG. 5 shows the structure of FIG. 4 after etching by ion milling to remove part of the TiO 2 —platinum—TiO 2 layers, i.e., the part that is not substantially shielded by the patterned photoresist 148 .
- the etching stops at the TiO 2 —silicon nitride interface.
- the TiO 2 —platinum—TiO 2 layers remaining has a trapezoidal sectional view.
- the term “trapezoid” is used herein to refer to the lines (branches) having a trapezoidal cross-section, although the lines (branches) in the mesh also has an elongated dimension.
- the TiO 2 —platinum—TiO 2 trapezoids 150 , 151 had an angle of about 45° plus or minus about 5° between the slope side of the trapezoids 150 , 151 and the base thereof.
- the etching is patterned to form lines (or branches) of the micro-mesh about 10 microns wide and having gaps of about 15 microns between neighboring lines (or branches).
- a second layer of dielectric material such as a 0.5 micron thick layer of LPCVD silicon nitride 152 is layered on the structure, forming the structure of FIG. 6 .
- the resulting structure is then annealed at 850° C. for 24 hours.
- part of the second dielectric i.e., the silicon nitride layer 152
- the metal layer of the trapezoids 150 which are to be used for forming the bond pads, such as bond pad A 118 , bond pad B 120 .
- the part of the silicon nitride layer 152 over trapezoids 151 for covering the resistor is not removed. This can be accomplished by having a patterned photoresist 154 to protect areas in which the removal of the second dielectric layer 152 is not desired.
- photoresist layer 156 is formed on the trapezoids 150 to protect them and the photoresist 154 , as well as dielectric material 140 , 152 about the trapezoids 151 are dry-etched, resulting in a structure shown in FIG. 8 .
- the dry etch can be done with various techniques, including ion milling, plasma etch, reactive ion etch, and the like.
- the photoresist material 154 , 156 is removed and a thin layer of titanium-tungsten (Ti—W) 160 (about 200 ⁇ to 500 ⁇ thick) is deposited on the resulting structure, shown in FIG. 9 .
- Ti—W adhesion promotion materials or “adhesive materials” for bonding gold, platinum, etc., are known in the art. Further, one skilled in the art will know the variation of the ratio of titanium to tungsten to use.
- a patterned photoresist layer 162 is formed on the structure of FIG. 9 to protect the area on which a conductor layer is not desired (e.g., a gold layer for providing electrical conduction), resulting in a structure shown in FIG. 10 .
- FIG. 11 shows that subsequently gold 164 is deposited, e.g., by electroplating on the structure of FIG. 10 .
- the gold layer 164 formed to be used for bonding to an external electronic component as a bond pad, will be substantially thicker than the titanium-tungsten.
- Such a gold strip when made by adhering via a Ti—W adhesive layer on a metal oxide (e.g., TiO 2 ) adhesive layer is isolated from the underlying first conductor (e.g., platinum micro-mesh) by the metal oxide in areas in which the micro-mesh and the gold strip overlap.
- the resulting structure is shown in FIG. 13 .
- the bonding from the platinum film 144 to the contact metal, e.g., gold layer 164 provides electrical conduction.
- the adhesive strength between them is relatively weak.
- the contact metal e.g., gold layer 164
- the dielectric (e.g., silicon nitride) layer is secured to the micro-mesh.
- the dielectric material and the micro-mesh conductor metal have different coefficients of thermal expansion. Because of its ability to reduce stress, the micro-mesh structure allows the micro-mesh conductor metal to be secured to the dielectric material, as well as to the bond pad, without separating even after undergoing cycles of temperature change.
- the conductor metal that is laid on the micro-mesh area reaches into the void area 149 and attaches to the dielectric material (e.g., nitride layer) via the Ti—W adhesion promotion layer 160 .
- the dielectric material e.g., nitride layer
- FIG. 14A shows an alternative embodiment for attaching a conductor metal to a micro-mesh to form a bond pad.
- “volcano” section-shaped structures 176 are used for adhering conductively to the contact metal (e.g., gold 164 ) in a bond pad 118 .
- the second adhesive layer 170 which is laid on top of the micro-mesh metal (platinum film) 172 has a well 174 opening to the top of the volcano section-shaped structures 176 .
- the well 174 extends to the conductor metal (platinum film) to provide electrical connection from the conductor metal (e.g. gold) 164 , such as the conductor metal in bond pads.
- the walls 180 of the well 174 provide adhesive surface for binding to the conductor metal (e.g., gold 164 ).
- FIG. 14B shows yet another variation of a micro-mesh in the present invention.
- the conductor metal e.g., gold
- the top adhesive layer 170 do not need to be extensively removed by etching, or the well does not need to reach to the platinum. This allows for more freedom in the use of the adhesive layer.
- the micro-mesh of the present invention for providing stable attachment and electrical connection to conductor metal to result in bond pads (conductor pads), conductor passages, and the like can have a variety of patterns.
- the micro-mesh can have a grid pattern as that shown in conductor micro-mesh A of FIG. 3 .
- the grid can have a variety of patterns: square (FIG. 15 A), rectangle (FIG. 15 B), or parallelogram (FIG. 15 C), such as a rhombus.
- Other applicable patterns include, but are not limited to, triangle (FIG. 16 A), hexagon (FIG. 16 B), combination of various patterns, and even a relatively irregular pattern.
- the micro-mesh of the present invention is useful not only for forming a bond pad, but also for forming a conductor passage, for example one leading from the heater (resistor) to the bond pad, such as conductor A 114 and conductor B 116 .
- a conductor passage for example one leading from the heater (resistor) to the bond pad, such as conductor A 114 and conductor B 116 .
- the electrical resistance a conductor passage should be 1% or less, preferably 0.1% or less, of the resistance of the resistor.
- the width of conductor passage would need to be adequately wide, which, if the conductor is made of a metallic substance that does not adhere well to the dielectric material, might lead to delamination of the conductor passage from the dielectric material.
- the micro-mesh of the present invention will be useful.
- the technique of construction of the conductor passage will be similar to the technique for making the bond pad. However, in the construction of such a conductor passage, the top gold layer and the Ti—W adhesion promotion layer are not needed. Instead, the metallic micro-mesh can be covered by nonconductors (e.g., the second adhesive layer 146 and a nitride layer thereon).
- the heater can be made with platinum and the micro-meshes at the bond pad and at the conductor passage can be made from copper, gold, aluminum, and the like, or any metallic electrically conductive material. Further, the resistor can be made with other metallic materials as well.
- the techniques of the present invention will provide a conductor metal that adheres well to a dielectric layer such that blister formation is substantially reduced or eliminated.
- a conductor metal that adheres well to a dielectric layer such that blister formation is substantially reduced or eliminated.
- platinum is used as a filament.
- a dielectric such as PECVD silicon nitride
- hydrogen is present and may dissolve in the dielectric.
- PECVD is Plasma Enhanced Chemical Vapor Deposition. To form a silicon nitride layer, enough energy must be provided to the molecules to break them down so they can recombine to form the desired molecule.
- PECVD energy is provided by the plasma (whereas in LPCVD, the energy comes in the form of thermal energy). While the gas has high temperature, the substrate can be at a much lower temperature. Typical deposition temperature for PECVD nitride or silicon oxynitride is about 400° C. Such a detector device can undergo repeated cycling of the platinum filament between high and low temperatures in episodes of high temperature operation and still retain its integrity.
- platinum micro-mesh with wires i.e., lines or branches
- wires i.e., lines or branches
- a silicon nitride layer on a substrate by means of a TiO 2 adhesive layer.
- an area of platinum about 30 microns by 30 microns with no holes in it (i.e., it is not a mesh structure).
- some blistering was observed in the 30 microns by 30 microns area indicating the separation of the platinum film from the silicon nitride underneath it. No blister was seen in the micro-mesh area.
- the electrically conductive micro-mesh can be formed on a polymeric dielectric material to provide a bond that is resistant to delamination.
- the dielectric material can itself be the supporting substrate. This is true for dielectric materials such as silicon nitride, and is especially true for polymeric materials which can be shaped by micromachining mechanically, by laser ablation, molding, or wet etching.
- a heat resistant polyimide can be used as the dielectric for making an electrical component that has a metal micro-mesh laid thereon for conducting electricity in a device that can operate up to 300° C.
- An example of a applicable polyimide is KAPTON or UPILEX from DuPont (Wilmington, Del.). Such an electrical component is illustrated in FIG.
- a metal adhesive material 190 such as titanium, or titanium tungsten, can be used. It is to be understood that structures such as resistors, bond pad, etc. can be made by adhering gold to platinum on a polymeric dielectric material. Further, it is to be understood that a conductor micro-mesh can be attached to a dielectric without a separate adhesive layer. For example, titanium itself can be attached to polyimide or silicon nitride without using a different material as an adhesive. Also, inorganic dielectric materials other than silicon nitride can be used, e.g., aluminum oxide, aluminum nitride, titanium oxide, silicon dioxide, various types of glass, quartz, and the like.
- resistors and conductors can be made and used in ways similar to the above-describe embodiments of a flow sensor.
- a thermal conductivity sensor or detector TCD
- TCD thermal conductivity sensor or detector
- TiO 2 in the above describe embodiment can be replaced with other adhesive materials known in the art, such as titanium, chromium, titanium-tungsten alloy, nickel-chromium alloys, other metal oxides, including nickel oxide (Ni 2 O 3 ), chromium oxide (Cr 2 O 3 ), aluminum oxide (Al 2 O 3 ), tantalum oxide (Ta 2 O 3 ), and the like.
- other than platinum examples of alternative conductor material including nickel-iron (permalloy), nickel, and gold can also be used.
- examples of alternative dielectric material that can be used include silicon dioxide and silicon carbide.
Abstract
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Cited By (11)
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EP1401250A1 (en) * | 2002-09-17 | 2004-03-24 | Hewlett-Packard Development Company, L.P. | Electrodes with a mesh structure |
US20090060518A1 (en) * | 2007-08-29 | 2009-03-05 | Wang Tak K | Methods and apparatuses for providing a hermetic sealing system for an optical transceiver module |
CH704884A1 (en) * | 2011-04-29 | 2012-10-31 | Suisse Electronique Microtech | Substrate for receiving electrical contacts. |
US9373234B1 (en) * | 2015-01-20 | 2016-06-21 | 3D Fuse Technology Inc. | Security tape for intrusion/extrusion boundary detection |
US9466777B2 (en) * | 2015-02-03 | 2016-10-11 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
DE102014104976B4 (en) * | 2013-04-29 | 2017-07-06 | Toyota Jidosha Kabushiki Kaisha | Printed circuit boards with temperature management features and temperature management devices having the same |
US20170285438A1 (en) * | 2016-04-04 | 2017-10-05 | Sumitomo Electric Industries, Ltd. | Mach-zehnder modulator, method for fabricating mach-zehnder modulator |
US9844148B2 (en) | 2014-09-10 | 2017-12-12 | Cellink Corporation | Method of forming a circuit for interconnecting electronic devices |
US10211443B2 (en) | 2014-09-10 | 2019-02-19 | Cellink Corporation | Battery interconnects |
US11765822B1 (en) * | 2020-09-03 | 2023-09-19 | Marvell Asia Pte Ltd | Printed circuit boards with meshed conductive structures |
US11888180B2 (en) | 2021-03-24 | 2024-01-30 | Cellink Corporation | Multilayered flexible battery interconnects and methods of fabricating thereof |
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Publication number | Priority date | Publication date | Assignee | Title |
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EP1401250A1 (en) * | 2002-09-17 | 2004-03-24 | Hewlett-Packard Development Company, L.P. | Electrodes with a mesh structure |
US20090060518A1 (en) * | 2007-08-29 | 2009-03-05 | Wang Tak K | Methods and apparatuses for providing a hermetic sealing system for an optical transceiver module |
US7841781B2 (en) | 2007-08-29 | 2010-11-30 | Avago Technologies Fiber Ip (Singapore) Pte. Ltd. | Methods and apparatuses for providing a hermetic sealing system for an optical transceiver module |
CH704884A1 (en) * | 2011-04-29 | 2012-10-31 | Suisse Electronique Microtech | Substrate for receiving electrical contacts. |
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DE102014104976B4 (en) * | 2013-04-29 | 2017-07-06 | Toyota Jidosha Kabushiki Kaisha | Printed circuit boards with temperature management features and temperature management devices having the same |
US9844148B2 (en) | 2014-09-10 | 2017-12-12 | Cellink Corporation | Method of forming a circuit for interconnecting electronic devices |
US10964931B2 (en) | 2014-09-10 | 2021-03-30 | Cellink Corporation | Battery interconnects |
US10211443B2 (en) | 2014-09-10 | 2019-02-19 | Cellink Corporation | Battery interconnects |
US9373234B1 (en) * | 2015-01-20 | 2016-06-21 | 3D Fuse Technology Inc. | Security tape for intrusion/extrusion boundary detection |
US9832857B2 (en) * | 2015-02-03 | 2017-11-28 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
US20180063943A1 (en) * | 2015-02-03 | 2018-03-01 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
US10172229B2 (en) * | 2015-02-03 | 2019-01-01 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
US20170034902A1 (en) * | 2015-02-03 | 2017-02-02 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
US10542616B2 (en) * | 2015-02-03 | 2020-01-21 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
US9466777B2 (en) * | 2015-02-03 | 2016-10-11 | Cellink Corporation | Systems and methods for combined thermal and electrical energy transfer |
US20170285438A1 (en) * | 2016-04-04 | 2017-10-05 | Sumitomo Electric Industries, Ltd. | Mach-zehnder modulator, method for fabricating mach-zehnder modulator |
US10185204B2 (en) * | 2016-04-04 | 2019-01-22 | Sumitomo Electric Industries, Ltd. | Mach-Zehnder modulator, method for fabricating Mach-Zehnder modulator |
US11765822B1 (en) * | 2020-09-03 | 2023-09-19 | Marvell Asia Pte Ltd | Printed circuit boards with meshed conductive structures |
US11888180B2 (en) | 2021-03-24 | 2024-01-30 | Cellink Corporation | Multilayered flexible battery interconnects and methods of fabricating thereof |
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